Composite lintel system

ABSTRACT

A composite lintel structure is disclosed for spanning openings in a building structure and for supporting building materials thereon. The composite lintel structure has a vertical leg for affixation to a building structure and a horizontal leg for placement of one or more courses of building materials thereon. The materials of construction of the lintel structure are preferably selected from composites that are moisture impermeable and corrosion resistant. The lintel structure may also comprise one or more stiffeners rigidly or adjustably attached between the horizontal and vertical legs to accommodate load transference from the horizontal leg to the vertical leg of the lintel structure.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a lintel system for supporting bricksand other veneers above openings in a building structure. Morespecifically, the present invention comprises a composite lintel that islighter and more corrosion resistant as compared to conventional steellintels. The lintel has a variety of configurations to accommodatevarious areas of a building structure that require the use of a loadbearing support member.

2. Description of the Prior Art

Brick and concrete structures are common in the prior art. Manystructures are built from brick, concrete and the like because of theirmany advantages including: durability and strength; fire resistance;temperature and sound insulation; general attractiveness; and ease ofmaintenance, i.e., elimination of the rotting, denting, warping,rusting, splitting, peeling, and fading associated with woodenstructures, as well as a deterrent to wood consuming insects such astermites.

It should be understood that the facing material described hereinafteras brick can also be concrete, cinderblock, stone, granite, slate,mortar and other structural materials and veneers and combinationsthereof. It is necessary when building a brick structure for thebrickwork to be supported over openings. Methods for accomplishing thissupport include brick arches, steel bars or angles, prefabricatedreinforced concrete, prefabricated brickwork and directly support from areinforced concrete structure. The steel angles (known as lintels orshelf angles) can provide all the support, or be attached to the primarystructure such as a reinforced concrete frame, to which the load istransferred.

It is necessary (and required by building codes) when building a brickstructure to provide support over openings in the building structure.These are known generally as lintels, but also include arch supports,angle iron and roof supports, all of which hereinafter shall be referredto singularly and collectively as lintels. As is well known in the art,a lintel is a horizontally disposed architectural member that isemployed to span an opening in a building such as a window or door, andthe lintel usually carries the load above that opening. The lintels usedin modern buildings of cement block, brick, types of masonryconstruction have traditionally been fabricated of elongated heavy gageangle iron. Lintels are generally made of steel or concrete becausethese materials are durable and inexpensive. The lintel is typicallynailed, bolted or otherwise secured to the header (building frame)forming the top of the opening. It may additionally be simply supportedat each end by the brick or concrete just below the header outside theopening. One or more courses of brick are then placed on the lintel andare secured thereto with mortar. The lintel supports the weight of allthe bricks above the lintel (at least until the next support structureon the frame of the building.

Typically, a single L-shaped angle iron is employed by placement of theangle iron above the opening and the vertical portion of the angle ironis secured to the header or other support frame of the underlyingstructure. Alternatively, a pair of such angle members may be employedto form a lintel by placement of the members in a back-to-back positionover the opening in the building. This positioning results in a pair ofjuxtaposed upstanding flanges and a pair of oppositely laterallyextending flanges. In some instances the pair of upstanding flanges aresecured to each other such as by tack welding.

One particular size of angle iron member commonly used in forming theabove described prior art lintels measures 3 inches tall by 3½ inchesper leg, and are of ¼ inch thick metal. Each angle iron of thesedimensions will weigh approximately 5.8 pounds per lineal foot. Otherlarger angle irons are used when the span and load requirementsnecessitate the use of such heavier metal.

A problem with steel angle irons is that they are heavy and that steelbends under a sufficient load. When spanning an opening the steel (orother metal) angle iron will sag in the center between the simplesupports at the edges of the opening in the structure. In fact, theweight of the steel in the angle iron alone will cause it to deform—thissagging is compounded by the additional weight of the brickwork abovethat is to be supported by the sagging member. The sagging of the memberwill cause cracks and weakening of the brick structure above,necessitating eventual replacement of the lintel and brickwork. Thecracks in the brickwork will also cause moisture to enter beneath thebrickwork thereby damaging the underlying structure and exposing it towood infesting insects.

Steel angle iron typically should be protected against corrosion byhot-dip galvanizing. The density of the galvanization will depend on thecorrosive level of the environment, however stainless steel can also beused in highly corrosive environments. The angle iron may also beprotected from corrosion with paint or some other coating that protectsexposed areas from corrosion.

It is another problem with steel angle iron that by its nature, steel(or other metals) will expand and contract due to thermal expansion.This thermal expansion will inevitable cause such coatings as paint orgalvanization to be decimated over time and allow the underlying steelto be exposed to moisture, thereby causing corrosion. Furthermore,because these coatings are relatively thin, they are easily damagedduring shipping and installation of the angle iron. Only a small amountof exposed metal is necessary to commence the corrosion process in largeareas of the angle iron.

Furthermore, corrosion of the angle iron creates greater problems. Bytheir nature brick and concrete are very porous. Water can easilypermeate the typical brick or concrete block. This is the reasondrainage devices (called weep holes) are typically built into theseveneers in order to prevent accumulation of moisture between the veneerand the underlying structure of the building. Accumulation of moisturecan cause damage to the underlying wooden or metal structure. However,some moisture is still retained between the veneer and the structure.This inevitably leads to corrosion of exposed metal members in thestructure, i.e., steel angle irons used as lintels.

Corrosion of the steel lintel can cause diagonal cracks to extend upfrom the ends of the lintel. The corrosion product of steel will occupy10 to 20 times as much space as the steel itself. This expansiongenerates tremendous pressure when confined and is capable of bendingthe steel angles. As mentioned herein above, this bending fromcompression and sagging is capable of breaking apart the brick masonry,or lifting the brick, thereby necessitating replacement of the angleiron and brickwork.

Corrosion that builds up on the top surface of the steel lintel liftsthe masonry. Diagonal cracks form at the ends of the lintel because thisarea is the weakest plane. The cracks are more likely to occur whenthere are only a few feet of masonry above the head of the windowsbecause there is less weight to resist the expansion pressure generatedby the corroding steel. Where there is greater confining pressure, suchas at lower levels on a building that does not contain horizontalexpansion joints, the pressure generated by the corroding steel causesthe portion of the angle above the window to deflect downward and thebrick at the jambs to crush. To repair this problem, it is oftennecessary to replace the lintel with a new one. Typically, three to fourcourses of the exterior brick masonry must be removed in order toperform this repair. This is very expensive.

Therefore, a need exists for a new and improved lintel structure whichcan be fabricated from relatively light composite materials which havesufficient structural strength, as well as being resistant to corrosion.

The prior art includes lintel and support structures as in U.S. Pat. No.4,020,612 to Welch. Welch describes a lintel fabricated of an elongatedlightweight metal plate having rigidifying beam means affixed theretoand extending longitudinally thereof. Although the lintel of Welchattempts to provide for a lightweight and rigid member, the device ofWelch still does not provide for a corrosion resistant structure.

U.S. Pat. No. 5,584,150 to Newman discloses an angle iron cover, whichmay be made of plastic that may be removably secured to an angle iron.The purpose of Newman is to provide an aesthetic cover for exposedportions (primarily the bottom) of angle irons. Although Newman providesa plastic cover for some of the lintel, the device of Newman does notprevent corrosion because portions of the angle iron are still exposedto moisture. Furthermore, the device of Newman does not providelightweight of rigidity to the lintel, and thus suffers the disadvantageof sagging under its own weight and that of the bricks thereabove.

U.S. Pat. No. 4,106,247 to Svensson describes a lintel made of arelatively thin plate having an L-shaped cross-section. The device ofSvensson described tension band attached between the horizontal andhorizontal legs 20 of the lintel. Although the lintel of Svenssonattempts to provide for a relatively lightweight and rigid member, thedevice of Svensson still does not provide for a corrosion resistantstructure.

Thus, the prior art devices identified above suffer a host ofdisadvantages. None of the devices above provide for a lintel structurethat is both lightweight yet structurally rigid while also beingcorrosion resistant. A plastic cover for only a portion of the steellintel does not prevent corrosion, and galvanized structures still arenot corrosion resistant as the galvanization is easily damaged duringtransport and installation.

Accordingly, it is an object of the present invention to provide a newand useful lintel structure.

Another object of the present invention is to provide a lintel structurethat is made of composite materials such that it is lightweight comparedto prior art lintels.

Another object of the present invention is to provide a lintel structureof the above-described character that is formed of composite materialsthat have sufficient structural strength to support the brickworkthereon.

Another object of the present invention is to provide a lintel structureof the above-described character that is formed of composite materialsand is simple and relatively inexpensive to fabricate.

Another object of the present invention is to provide a lintel structureof the above-described character that is formed of composite materialshaving a rigidifying means affixed thereto.

Another object of the present invention is to provide a lintel structureof the above-described character that is formed of composite materialssuch that it is moisture impermeable.

Another object of the present invention is to provide a lintel structureof the above-described character that is formed of composite materialssuch that it is corrosion resistant.

The foregoing and other objects of the present invention, as well as theinvention itself, may be more fully understood from the followingdescription when read in conjunction with the accompanying drawings.

SUMMARY OF THE INVENTION

In accordance with the present invention, a new and useful lightweightmoisture impermeable lintel structure is disclosed as being fabricatedof an elongated composite shelf angle having a rigidifying means affixedthereto. The rigidifying means comprises spaced apart stiffeners thatare disposed in integral multiples of the brick lengths (including spacefor the mortar therebetween). The preferred form of stiffeners is arelatively light gage composite material in the form of triangularmembers attached between the vertical and horizontal legs of thecomposite shelf angle. Accordingly, it is an object of the presentinvention to provide a new and useful lintel structure.

Thus, an object of the present invention is to provide a lintelstructure that is made of composite materials such that it islightweight compared to prior art lintels, thereby minimizing orpreventing sagging of the lintel.

Another object of the present invention is to provide a lintel structureof the above-described character that is formed of composite materialsthat have sufficient structural strength to support the brickworkthereon, thereby minimizing or preventing sagging of the lintel.

Another object of the present invention is to provide a lintel structureof the above-described character that is formed of composite materialsand is simple and relatively inexpensive to fabricate.

Another object of the present invention is to provide a lintel structureof the above-described character that is formed of composite materialshaving a rigidifying means affixed thereto, thereby minimizing orpreventing sagging of the lintel.

Another object of the present invention is to provide a lintel structureof the above-described character that is formed of composite materialssuch that it is moisture impermeable.

Another object of the present invention is to provide a lintel structureof the above-described character that is formed of composite materialssuch that it is corrosion resistant.

Additional objects and advantages of the invention will be set forth inpart in the description that follows, and in part will be obvious fromthe description, or may be learned by practice of the invention. Theobjects and advantages of the invention will be obtained by means ofinstrumentalities in combinations particularly pointed out in theappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate a complete embodiment of theinvention according to the best modes so far devised for the practicalapplication of the principles thereof, and in which:

FIG. 1 is a perspective view a prior art angle iron.

FIG. 2 is a side view of a prior art angle iron showing the operablerelationship between the lintel, the underlying structure and thebrickwork supported thereon.

FIG. 3 is a perspective view showing the preferred embodiment of thecomposite lintel of the present invention.

FIG. 4 is a partially cross-sectional front elevation view showing thepreferred embodiment of the composite lintel of the present invention.

FIG. 5 is a partially cross-sectional side elevation view showing thepreferred embodiment of the composite lintel of the present invention.

FIG. 6 is a cross-sectional view of the composite lintel showing aninterior frame encased in a composite material.

FIG. 7 is a cross-sectional view of the composite lintel showing aninterior frame encased in a textured composite material and furthershowing affixation holes and weep holes.

FIG. 8 is a cross-sectional view of a preferred configuration of anangled affixation hole with fastener and sealant.

FIG. 9 is a front-elevation view of a lintel structure having anadjustable stiffener slideably mounted within the vertical andhorizontal legs.

FIG. 10 is a cross-sectional view of the lintel and stiffener of FIG. 9.

FIG. 11 is an elevation view of a lintel structure having an adjustablestiffener slideably mounted over the vertical and horizontal legs.

FIG. 12 is a cross-sectional view of the lintel and stiffener of FIG.11.

FIG. 13 is a cross-sectional view of another embodiment of the linteland stiffener of FIG. 11.

FIG. 14 is perspective view of a lintel structure having an adjustablestiffener mounted to the vertical and horizontal legs with T-channelsand snap fasteners.

FIG. 15 is a cross-sectional view of the lintel and stiffener of FIG.14.

FIG. 16 is perspective view of a lintel structure having an adjustablestiffener mounted to the vertical and horizontal legs with dovetailedchannels.

FIG. 17 is a cross-sectional view of the lintel and stiffener of FIG.16.

FIG. 18 is a cross-sectional view of another configuration for thedovetails for the lintel and stiffener of FIG. 16.

FIG. 19 is a front elevation view of a lintel structure configured inthe form of a roof, dormer or eave angle.

FIG. 20 is a front elevation view of a lintel structure configured inthe form of an arched lintel.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the figures where similar parts are numbered the samethroughout. FIG. 1 is a perspective view of a typical embodiment of anangle iron used as a lintel in the prior art. As mentioned herein above,the angle iron typically comprises steel bar having an L-shapedcross-section. FIG. 2 shows the typical configuration of a prior artangle iron affixed to a building structure and having bricks and mortarsupported thereon.

Referring now to FIGS. 3-5: FIG. 3 is a perspective view of thepreferred embodiment of the invention. In this embodiment, the lintel 1comprises a composite structure having a generally L-shapedcross-section. The lintel 1 has a vertical leg 20 which is affixed tothe underlying structure (building header or frame above the opening)and which is rigidly attached to a horizontal leg 10, upon which bricksand mortar are laid.

The materials of construction of the vertical leg 20 and horizontal leg10 of the lintel 1 are preferably composite materials that arelightweight (relative to the prior art steel composition). In thepreferred embodiment of the invention, the primary material ofconstruction of the lintel 1 is preferably a thermoplastic material thatis lightweight and has a high tensile strength. Examples of suchpreferred thermoplastics includes Acrylic, ABS (and glass fiberreinforced ABS), Acetyl Copolymer (AC and glass reinforced AC), HighDensity PolyEthylene (HDPE), Ultra High Molecular Weight PolyEthylene(UHMPE), Nylon (including heat stabilized, impact modified,glass-filled, polyamide and copolymer flame retardant nylons, andcombinations thereof), Polycarbonate, Polypropelene, Polyimide (PI andglass fiber reinforced PI), Polyamide-Imide, Polystyrene, Teflon™, andEpoxies.

More specifically, the substances that may be used as a compositeconstruction of or coating for a composite lintel include:Acrylonitrile/Methylacrylate copolymer; Regenerated Cellulose; CelluloseAcetate (CA); Cellulose Acetate Butyrate (CAB); Cyclo-olefin copolymer;Ethylene-Chlorotrifluoroethylene copolymer (E-CTFE);Ethylene-Tetrafluoroethylene Copolymer (ETFE); Fluorinated EthylenePropylene Copolymer (FEP); Polyacrylamide/acrylate Hydrogel;Hexafluoropropylenevinylidenefluoride copolymer (FKM); Polyacrylonitrile(PAN); Polyacrylonitrile-butadiene-styrene (ABS); Polyamide—Nylon 4,6(PA 4,6); Polyamide—Nylon 6 (PA 6); Polyamide—Nylon 6, 6 (PA 6,6);Polyamide—Nylon 6, 6-30% Glass Fiber Reinforced (PA 6,6 30% GFR);Polyamide—Nylon 11 (PA 11); Polyamide—Nylon 12 (PA 12); Polyamide/imide(PAI); Polyaramid Polyparaphenylene terephthalamide; PolyaramidPolymetaphenylene isophthalamide; Polybenzimidazole (PBI); Polybutyleneterephthalate (PBT); Polybutylene terephthalate—30% Glass FiberReinforced (PBT 30% GFR); Polycarbonate (PC); Polycarbonate—30% GlassFibre Filled; Polychlorotrifluoroethylene (PCTFE); Polyetheretherketone(PEEK); Polyetherimide (PEI); Polyethersulfone (PES);Polyethylene—Carbon filled; Polyethylene—High density (HDPE);Polyethylene—Low Density (LDPE); Polyethylene—Ultra High molecularWeight (UHMW PE); Polyethylene naphthalate (PEN); Polyethyleneterephthalate Polyester, (PET, PETP); iPolyhydroxybutyrate—Biopolymer(PHB); Polyhydroxybutyrate/Polyhydroxyvalerate 8%—Biopolymer (PHB92/PHV8); Polyimide (PI); Polymethylmethacrylate (PMMA); Acrylic;Polymethylpentene; Polyoxymethylene—Copolymer Acetal—Copolymer (POMC);Polyoxymethylene—Homopolymer Acetal—Homopolymer (POMH);Polyphenyleneoxide PPO (modified), PPE (modified); Polyphenyleneoxide(modified), 30% Glass Fiber Reinforced (PPO 30% GFR);Polyphenylenesulfide (PPS); Polyphenylenesulfide—40% Glass FiberReinforced (PPS—40% GFR); Polyphenylsulphone; Polypropylene (PP);Polystyrene (PS); High Impact Conductive Polystyrene;Polystyrene—Cross-linked (PS—X—Linked); Polytetrafluoroethylene (PTFE);Polytetrafluoroethylene coated Glass Fabric (PTFE 75/Glass 25);Polytetrafluoroethylene filled with Glass (PTFE 25% GF);Polyvinylchloride—Unplasticized (UPVC); Polyvinylfluoride (PVF);Polyvinylidenechloride (PVDC); Polyvinylidenefluoride (PVDF); SiliconeElastomer; and Tetrafluoroethylene-perfluoro(alkoxy vinylether)—Copolymer PFA. (Teflon PFA).

As an example of the properties of HDPE which make it desirable as amaterial for a light-weight corrosion resistant (moisture impermeable)material of construction for a lintel structure are the followingproperties: HDPE has a density of 0.0338-0.0348 lb/in³ (0.948 g/cc);Water Absorption of 0.01%; Moisture Vapor Transmission of 0.965cc-mil/100 in²-24 hr-atm; Tensile Strength of 3480-6530 psi (30 Mpa);Yield Strength of 2180-4350 psi (21.9 Mpa); a Tensile Modulus 116-144ksi (0.86 Gpa); a Flexural Modulus of 72.5-220 ksi (0.928 Gpa); a linearCoefficient of Thermal Expansion (CTE) at 20° C. of 77.8 pin/in; and aMelting Point of 255-268° F. (130° C.). Thus desirable physicalproperties include low density for light weight (0.5-3.0 g/cc); LowWater absorption (less than 0.1%); a low CTE (less than 250 pin/in);relatively high melting point (more than 160° F./60° C.); High tensilestrength of (15-100 Mpa); High Yield Strength (5-40 Mpa); a relativelyhigh Tensile Modulus (0.5-2.5 Gpa); a relatively high Flexural Modulus(0.7-4.0 Gpa)

Preferably, the lintel 1 also comprises at least one stiffener 30 thatis an essentially triangular member attached to both the vertical andhorizontal legs 20, 10 of the lintel 1. The triangular, i.e, righttriangular, stiffener 30 has a substantially vertical back edge and asubstantially horizontal bottom edge, with a diagonal front edgeextending from the front of the bottom edge to the top of the back edgeof the stiffener 30. The stiffener 30 adds strength to the compositestructure by distributing the load born by the horizontal leg 10 andtransferring a portion of the load to the stiffener 30 and the verticalleg 20 of the lintel 1. The stiffeners 30 are preferably attached to thevertical and horizontal legs 20, 10 and extend substantiallyperpendicularly to the vertical and horizontal legs 20, 10 of the lentil1, i.e. at a 90 degree angle to the front face 20 a of the vertical leg20 and at a 90 degree angle to the top face 10 b of the horizontal leg10. The stiffeners 30 are preferably distributed along the length of thevertical and horizontal legs 20, 10 by an integral number of bricklengths (including mortar thickness between vertical adjoining brickfaces, in order to facilitate placement of one or more bricks betweeneach pair of stiffeners 30. Preferably the stiffeners 30 allow forplacement of two bricks (and mortar) therebetween. However, stiffeners30 may be spaced so as to allow placement of only one brick (and mortar)between adjacent stiffeners 30 or three or more bricks (and mortar)therebetween.

Each of the horizontal legs 10, vertical legs 20 and stiffeners 30 hasopposing surfaces that provide functionality to the composite lintel 1structure. The horizontal legs 10 have top and bottom opposing faces.The bottom face 10 a of the horizontal leg 10 is substantially flat andis typically the exposed surface of the lintel 1 beneath the openingthat the lintel 1 spans. The top face 10 b of the horizontal leg 10supports the bricks and/or mortar that are laid on the top face 10 b ofthe horizontal leg 10.

The vertical legs 20 have front and back opposing faces. The back face20 b of the vertical leg 20 is substantially flat and abuts theunderlying building structure to which it is attached. The front face 20a of the vertical leg 20 is adjacent to the bricks that are laid on thetop face 10 b of the horizontal leg 10. The stiffeners 30 areessentially triangular members connecting the top face 10 b of thehorizontal leg 10 to the front face 20 a of the vertical leg 20. Each ofthe stiffeners 30 has opposing left and right side faces and back andbottom edges. The back edge of the stiffener 30 is connected to thefront face 20 a of the vertical leg 20 and the bottom edge o thestiffener 30 is connected to the top face 10 b of the horizontal leg 10.

Referring to FIGS. 6-7: In order to increase the tensile and flexuralstrength of the lightweight composite lentil and comply with certainbuilding codes, another embodiment of the composite lentil 2 may alsoinclude a substrate 200 comprising metal frame/substrate or otherinterior support member located between the front and back faces 20 a,20 b of the vertical leg 20 and between the top and bottom faces 10 b,10 a of the horizontal leg 10. The substrate 200 may also be locatedbetween the opposing left and right side faces of the stiffeners 30 andrigidly connected to the top face 10 b of the horizontal leg 10 and thefront face 20 a of the vertical leg 20 of the lintel 1. Morespecifically, in this embodiment of a composite lintel 2 a solidinterior frame or substrate 200, comprises a vertical substrate leg 220rigidly attached to a horizontal substrate leg 210 constructed asdescribed above, which is located between the front and back faces 20 a,20 b of the (plastic) vertical leg 20 and between the top and bottomfaces 10 b, 10 a of the (plastic) horizontal leg 10. The substrate 200may have a stiffener 230 attached to the vertical and horizontalsubstrate legs 220, 210 as described herein above, and located betweenthe opposing left and right side faces 30 b, 30 c of the (plastic)stiffeners 30.

The material of construction of the substrate 200 may be selected fromthe group of high tensile and flexural strength metals such as iron,steel, aluminum, tin, titanium, beryllium and mixtures, oxides and metalalloys. The material of construction of the substrate may also beselected from the group of high strength materials such as carbon,carbon fibers, concrete and glass reinforced or carbon fiber reinforcedplastics and other materials having high tensile and flexural strength.Furthermore, the substrate may include various combinations of theaforementioned metallic and/or other composite materials.

The interior support structure may include for example solid substrates(vertical and horizontal legs 220, 210 of the substrate rigidly affixedto each other, and further including stiffeners 230 attachedtherebetween) which are encased in or coated with the aforementionedthermoplastic material. Furthermore, the composite lintel 2 may alsocomprise an interior frame or substrate that includes not only thehorizontal and vertical legs 210, 220, but also a stiffener 230 rigidlyattached to the horizontal and vertical legs 210, 220. Furthermore,rather than a solid interior frame, the substrate or support structuremay include a mesh, wire frame or particulate composite disposition ofthe aforementioned materials of composition. In addition, in order tocomply with building codes, the substrate and/or composite may alsocomprise fire and/or heat resistant compositions including asbestosand/or carbon.

Preferably the overall thickness of the lentil legs 10, 20 andstiffeners 30 is 3/16 inch However, the horizontal leg 10 and thevertical leg 20 may range in thickness from as little as ⅛ inch to asmuch as 2 inches depending on the materials of construction of thelintel 1, 2 and their load bearing capabilities. Furthermore, thestiffeners 30 may range in total thickness from as little as 1/16 inchto as much as ½ inch depending on the materials of construction of thestiffeners 30 and their load bearing capabilities.

As mentioned herein above in one embodiment of the invention, thelightweight composite material (primarily a thermoplastic substance) maybe used alone or may be used to encase an interior support structure200. Preferably the thermoplastic is applied to the support structure200 by spray coating. However, the materials may be combined byinsertion of the support structure 200 within an extruded plasticcasing. The thermoplastic may also be heated to enhance adhesion of thecasing (vertical and horizontal legs 20, 10 and/or stiffeners 30) to theinternal support structure 200. The thickness of the casing ispreferably sufficient to prevent permeation of moisture therethrough andonto the support structure to prevent oxidation of the internalstructure 200. Preferably, the casing has a thickness of at least 10mils to ¼ inch thickness and the interior support 200 has a thicknessranging between 10 mils to ¼ inch thickness.

Referring to FIG. 7: To enhance adhesion of the mortar and/or bricks tothe surfaces of the lintel, i.e., the faces adjacent the bricks, thefront face 20 a of vertical leg 20 and/or the top face 10 b of thehorizontal leg 10 and stiffener 30 left and right faces 30 b, 30 c arepreferably textured such as a sanded, corrugated, dimpled and/orperforated texture. Such texturing enhances adhesion of mortar theretoand/or therethrough to provide a firm anchorage of the mortar and bricksto the faces of the vertical leg 20, horizontal leg 10 and/or opposingside faces 30 b, 30 c of the stiffeners 30.

In an exemplary embodiment, the above described lintel 1 is used with acourse of typical bricks. Modular bricks have typical nominal dimensionsof 4 inches in width (3 1/2-3⅝ inch) by 8 inches in length (7½- 7⅝ inch)and nominal heights of 2⅔, 3 1/5 and 4 inches, and a joint thickness(for mortar) of ⅜ to ½ inch. The stiffeners 30 are spaced 16 inches (oncenter) to be apart so as to allow placement of two bricks (15 inches)with a ⅜ to ½ inch of mortar between each adjoining brick side face, and3/16 to ½ inch of mortar between the brick side faces adjacent thestiffener faces 30 b, 30 c, as well as ¼-½ inch of mortar between thebrick bottom faces adjacent the top face 10 b of the horizontal leg 10of the lintel 1.

The front edges 30 a of the stiffeners 30 are angled from the top face10 b of the horizontal leg 10 toward the front face 20 a of the verticalleg 20. Preferably, the angle at which the stiffener 30 tends from thehorizontal leg 10 toward the vertical leg 20 allows for placement of asecond course of bricks on a first course of bricks in a staggeredfashion (which enhances the strength of the brickwork) such that thesecond course of bricks do not contact the front edge(s) 30 a of thestiffener(s) 30. Alternatively the stiffeners 30 may tend at an anglefrom the horizontal leg 10 toward the vertical leg 20 that is furthertowards vertical to enhance the load transference capability from thehorizontal leg 10 to the vertical leg 20. In this case, bricks may becut at the point that they would contact the front edge 30 a of thestiffener 30 to allow the front edge 30 a of the stiffener 30 toprotrude within the brick (or mortar therein). Preferably the angle isat least 45 degrees, and most preferably is approximately 30 degrees offvertical). The angle however may be in a range (off vertical) of 15 to75 degrees.

In order to enhance the load bearing capability of the horizontal leg 10of the lintel 1, the ratio between the height of the vertical leg 20 ofthe lintel 1 and the horizontal leg 10 of the lintel 1 (and that of theload transference by the stiffener 30) is preferably approximately 2-3,i.e., the length of the vertical leg 20 of the lintel 1 is two to threetimes the length of the horizontal leg 10 of the lintel 1. Thus, ataller vertical leg 20 and stiffener 30 allows greater load transferencethrough the stiffener 30 from the horizontal leg 10 to the vertical leg20. Although the vertical leg 20 is preferably at least twice as long asthe horizontal leg 10, the ratio between the legs may be as little as0.5, or as great as 5-10.

In an exemplary embodiment of the present invention, the horizontal leg10 is approximately 3⅝ inches in length and the vertical leg 20 isapproximately 10 inches in length, and both horizontal and horizontallegs 20 are approximately 5/16 inch in thickness. A stiffener 30(approximately 3/16 inch in thickness) extends along the top face 10 bof the horizontal leg 10 from the front face 20 a of the vertical leg 20approximately 3 inches, and also extends along the front face 20 a ofthe vertical leg 20 from the top face 10 b of the horizontal leg 10approximately 8 inches. Thus, the vertical leg 20 accommodates astiffener 30 of approximately 3×8 inches. Although the above exemplarydimensions are provide, the horizontal leg 10 may be as short range from3-5 inches, the vertical leg 20 may range from 3-24 inches, and thestiffener 30 may extend along all or a portion thereof of the verticaland horizontal legs 20, 10. Also the thickness of some or all of thevertical leg 20, horizontal leg 10 and stiffeners 30 may vary from ¼inch to 1 ½ inches, as necessary to accommodate the dimensions andweight of the brick or other construction materials supported by thelintel 1.

Although the back face 20 b of the vertical leg 20 of the lintel 1 maybe substantially vertical to lie directly against the front face 20 a ofthe underlying structure (header), it is preferred that the top portion25 of the vertical leg 20 be shaped to enhance moisture impermeabilityat the edge 27 of the top portion 27 vertical leg 20. More specifically,the top portion 25 of the vertical leg 20 of the lintel 1 preferably hasa radius of curvature R1 (towards the back face 20 b and underlyingbuilding structure) such that upon affixation of the lintel 1 to thebuilding structure, the top edge 27 exerts a force onto the front faceof the building structure thereby preventing moisture from permeatingfrom the building structure above the lintel 1 and the top edge 27 ofthe vertical leg 20 to between the back face 20 b of the vertical leg 20and the underlying building structure. The radius of curvature of thetop portion 25 of the vertical leg 20 is preferably approximately ¼ inch(toward the back face 20 b of the vertical leg 20), however a range ofcurvatures from 1/16 inch to 2 inches is sufficient for the top edge 27of the vertical leg 20 to exert a force on the building structure toprevent moisture from permeating from the top edge 27 of the verticalleg 20 to between the back face 20 b of the vertical leg 20 and theunderlying building structure.

Referring to FIGS. 3-5 and FIG. 7: The horizontal leg 10 preferably alsohas weep holes 50 therethrough running between the top and bottom faces10 b, 10 a of the horizontal leg 10 of the lintel 1 or 2. These holes 50allow any accumulated moisture in the bricks and/or mortar to drain outfrom the brick and/or mortar through the lintel 1 structure. Draining ofmoisture prevents accumulation of moisture in the veneer therebyminimizing moisture damage to the lintel 1 and the underlying structureto which the lintel 1 is affixed. In addition to the horizontal leg 10,the vertical leg 20 and the stiffeners 30 may also have weep holes 50therethrough. There is preferably at least one weep hole 50 per brickthrough the horizontal leg 10 of the lintel 1. However, there may be asfew as one weep hole 50 between each pair of stiffeners 30, and mostpreferably two or more weep holes 50 beneath each brick placed on thehorizontal leg 10 of the lentil 1. The weep holes 50 may be spaced atregular 8-inch intervals to accommodate each brick thereabove, or may berandomly distributed through the horizontal leg 10 of the lintel 1.Preferably, the weep holes 50 also have the thermoplastic composite onthe faces 50 a of the holes 50 (on the hole faces 50 a normal to the topand bottom faces 10 b, 10 a of the horizontal leg 10) to preventmoisture from contacting the substrate 200, thereby preventing oxidationof the substrate 200 within the composite lintel 2.

Referring to FIG. 8: In order to affix the lintel 1 to the underlyingbuilding structure, affixation holes 40 are provided through thevertical leg 20 of the lintel 1. The holes 40 allow placement of afastener 45 therethrough to allow for said fastener 45 to secure thevertical leg 20 of the lintel 1 to the underlying structure. Preferably,the affixation holes 40 also have the thermoplastic composite on thefaces 40 a of the holes 40 (on the hole faces 40 a normal to the frontand back faces 20 a, 20 b of the vertical leg 20) to prevent moisturefrom contacting the substrate 200, thereby preventing oxidation of thesubstrate 200.

There are preferably at least two affixation holes 40 through thevertical leg 20 of the lintel 1 on opposing ends of the vertical leg 20of the lintel 1. Also, there may be as few as one affixation hole 40between each pair of stiffeners 30, or there may be as many as two ormore affixation holes 40 for each brick placed on the horizontal leg 10of the lentil. Most preferably the affixation holes are spaced at 16inch intervals to accommodate placement of a fastener through theaffixation hole into a wall stud. Wall studs (2×4 or 2×6 boards formingpart of the building frame which are typically spaced 16 inches oncenter) provide a more secure attachment of the lintel 1 to theunderlying building structure.

The central axis of the securing/affixation holes 40 may be normal tothe front and back faces 20 a, 20 b of the vertical leg 20 of the lintel1 (as well as the abutting face of the underlying building structure).However, in the preferred embodiment of the invention, the securingholes 40 have an axis relating to the face of the underlying structureat substantially 45 degrees. More specifically, the holes 40 are relatedto the abutting face of the underlying building structure “downwardly”(approximately 45 degrees off vertical) to provide for greater loadtransference from the lintel 1 to the fastener 45 and from the fastener45 to the vertical leg 20, through the fastener 45 and to underlyingbuilding structure. The angle of the axis between the affixation hole 40and the face of the underlying structure can vary between 115 degreesand 15 degrees off vertical, but is preferably 45 degrees off vertical.

To enhance the moisture impermeability of the lintel 1 structure andfurther prevent corrosion, the affixation holes 40 are preferably filledwith a self-sealing substance 47 between the fastener 45 and theinterior (composite/plastic coated) walls 40 a of the affixation holes40. The self-sealing substance 47 preferably comprises tar, but may alsoinclude rubber, silicone, and other moisture impermeable sealingcompounds. Also to prevent the onset of corrosion, the materials ofconstruction of the fasteners 45/nails/screws are preferably selectedfrom the variety of corrosion resistant materials including galvanizedmetal, Teflon™, polyester, and the materials of construction listedherein above as the composite materials of construction of the lintelstructure. Thus when the fastener 45 is affixed through the affixationhole 40 to the underlying building structure, the self sealing substance47 forms a moisture impermeable layer between the fastener 45 and theaffixation hole 40 as well as a moisture impermeable barrier between thefastener 45, upper lintel 1 leg and the underlying building structure.Furthermore, the lintel 1 may be prefabricated with the fasteners 45already partially imbedded within the sealing compound 47 in theaffixation holes 40 in order to provide ease of installation.

Referring now to FIGS. 9-17 and 20: Although the above lintels show theconstruction material to be block shaped, as in conventional bricks andcinder block, it is within the scope of the invention to use othermaterials such as stone or composite materials having an non-uniform orirregular shape. To accommodate the use of building materials havingnon-uniform shapes, it is preferred that in an alternate embodiment ofthe lintel structure that the stiffener structures be adjustably orslideably mountable to the horizontal and vertical legs of the lintel asshown in FIGS. 9-18.

Referring now to FIGS. 9 and 10: FIG. 9 is a front elevation view of alintel structure 3 having an adjustable stiffener 60 slideably mountedwithin the vertical and horizontal legs 20, 10. More specifically, anadjustable stiffener 60 comprises a triangular stiffener 65 as describedabove mounted to a stiffener bracket 70 comprising horizontal andvertical bracket legs 72, 74. The overall dimensions of the vertical leg20, horizontal leg 10 and stiffener 65 of the lintel 3 are as describedabove in the embodiments of the lintels in FIGS. 3-8. Furthermore thematerials of construction of the lintel 3 are as described above in theembodiments of the lintels in FIGS. 3-8.

To accommodate the use of adjustable stiffener brackets 70, the top face10 b of the horizontal leg 10 and the front face 20 a of the verticalleg 20 have recesses 11, 12 therein allowing for insertion of thebracket 70 therein. More specifically, the horizontal bracket leg 72rests within the horizontal recess 11 in the horizontal leg 10 and thevertical bracket leg 74 rests within the vertical recess 12 in thevertical leg 20 of the lintel 3. Preferably the depth of the recesses11, 12 is approximately the same as the thickness of the horizontal andvertical bracket legs 72, 74. The thickness of the bracket legs 72, 74(and corresponding recesses 11, 12) is approximately ⅓ to ½ the overallthickness of the horizontal and vertical legs 10, 20 of the lintel 3.The width of the recesses 11, 12 is preferably 2-3 times the width ofthe bracket 70 to allow for left and/or right adjustment of the bracket70 within the recesses 11,12. The bracket is preferably at least ½ inchin width, and most preferably 3-4 inches in width. Thus the recesses 11,12 are preferably 2-12 inches in width to allow for adjustment of thebracket left or right by up to 11 inches. The recesses may alternatelyspan the entire length of a lintel for insertion of multiple stiffeners60 within the lintel recesses 11, 12.

The vertical bracket leg 74 has a first tongue 75 at the top end of thevertical bracket leg 74 and the horizontal bracket leg 72 has a secondtongue 73 at the front end of the horizontal bracket leg 72. The bracketlegs 72, 74 fit within the corresponding recesses 11, 12 in thehorizontal and vertical legs 10, 20 of the lintel 3. More specifically,the top end of the lintel recess 12 in the vertical leg 20 of the lintel3 has a first groove 14 (between the front and back faces 20, 20 b ofthe vertical lintel leg 20) to accommodate insertion of the first tongue75 of the vertical bracket leg 74, and retention of the vertical bracketleg 74 therein. The front end of the lintel recess 11 in the horizontalleg 10 of the lintel 3 has a second groove 13 (between the top andbottom faces 10 a, 10 b of the horizontal lintel leg 10) to accommodateinsertion of the second tongue 73 of the horizontal bracket leg, andretention of the horizontal bracket leg 72 therein.

To provide for securing of the adjustable stiffener 60 once it is placedin the desired position in the recesses 11,12, bracket affixation holes41 may be provided through vertical bracket leg 74 and through verticalleg 20 affixation holes 40 of the lintel 3, for placement of fasteners45 therethrough. Placement of a fastener 45 through the affixation holes40, 41 allows for attachment of the composite lintel 3 to the buildingstructure and fixation of the adjustable stiffener 60 relative to thelintel 3.

Referring now to FIGS. 11-13. FIG. 11 is an elevation view of a lintelstructure 4 having an alternate adjustable stiffener 80 slideablymounted over the vertical and horizontal legs 20, 10, i.e. around thetop edge and front edge of the vertical and horizontal legs 20, 10 ofthe lintel 4. The alternate adjustable stiffener 80 comprises atriangular stiffener member 85 rigidly attached to a stiffener bracket88. More specifically, a stiffener bracket 88 is provided having avertical leg front portion 82, and a horizontal leg top portion 84, towhich the back edge and bottom edge of the stiffener member 85 isrigidly attached. The vertical leg front portion 82 and the horizontalleg top portion 84 adjoin the front face 20 a and the top face 10 b ofthe vertical and horizontal legs 20, 10, of the lintel 4. The overalldimensions of the vertical leg 20, horizontal leg 10 and stiffener 85 ofthe lintel 4 are as described above in the embodiments of the lintels inFIGS. 3-8. Furthermore the materials of construction of the lintel 4 areas described above in the embodiments of the lintels in FIGS. 3-8.

The stiffener bracket 88 also comprises a vertical leg top portion 83rigidly attached vertical leg front portion 82. The vertical leg topportion 83 adjoins the top portion 25 of the vertical leg 20 of thelintel 4. The stiffener bracket 88 also comprises a horizontal leg frontportion 86 rigidly attached to the horizontal leg top portion 84. Thehorizontal leg front portion 86 adjoins the front face 10 c of thehorizontal leg 10 of the lintel 4. The stiffener bracket 88 alsocomprises a vertical leg back portion 81 rigidly attached vertical legtop portion 83. The vertical leg back portion 81 adjoins at least a partof the back face 20 b of the vertical leg 20 of the lintel 4. Thestiffener bracket 88 also comprises a horizontal leg bottom portion 87rigidly attached horizontal leg front portion 86. The horizontal legbottom portion 87 adjoins at least a part of the bottom face 10 a of thehorizontal leg 10 of the lintel 4. In the embodiment of FIG. 12, thestiffener bracket 88 has a vertical back portion 81 and a horizontal legbottom portion 87 that cover adjoin only a portion of the lintel'svertical leg 20 back face 20 b and horizontal leg 10 bottom face 10 a.In the embodiment of FIG. 13, the stiffener bracket 88 has a verticalleg back portion 81 and a horizontal leg bottom portion 87 that arerigidly connected to each other and adjoin the entirety (in the widthdimension of the bracket 88) of the lintel's vertical leg 20 back face20 b and horizontal leg 10 bottom face 10 a.

To accommodate the use of adjustable stiffener brackets 80, the top face10 b of the horizontal leg 10 and the front face 20 a of the verticalleg 20 may also have recesses 11, 12 therein allowing for insertion ofthe bracket 80 therein. More specifically, the top portion of thehorizontal bracket leg 84 rests within a horizontal recess 11 in thehorizontal leg 10 and the front portion 82 of the vertical bracket leg74 rests within the vertical recess 12 in the vertical leg 20 of thelintel 4. Preferably the depth of the recesses 11, 12 is approximatelythe same as the thicknesses of the top portion 84 of the horizontal legand the front portion 82 of the vertical leg. The thickness of thebracket portions 81, 82, 83, 84, 86, 87 (and corresponding recesses11,12) is approximately 1/10 to ¼ the overall thickness of thehorizontal and vertical legs 10, 20 of the lintel 4. The width of therecesses 11, 12 (if any) is preferably 2-3 times the width of thebracket 80 to allow for left and/or right adjustment of the bracket 80within the recesses 11, 12. The bracket is preferably at least ½ inch inwidth, and most preferably 3-4 inches in width. Thus the recesses 11, 12are preferably 2-12 inches in width to allow for adjustment of thebracket left or right by up to 11 inches. The recesses may alternatelyspan the entire length of a lintel for insertion of multiple stiffeners80 within the lintel recesses 11, 12.

To provide for securing of the adjustable stiffener 80 once it is placedin the desired position, bracket affixation holes 41 may be providedthrough the vertical bracket leg front portion 82 and/or rear portion 81and through vertical leg 20 affixation holes 40 of the lintel 4, forplacement of fasteners 45 therethrough. Placement of a fastener 45through the affixation holes 40, 41 allows for attachment of thecomposite lintel 4 to the building structure and fixation of theadjustable stiffener 80 relative to the lintel 4.

Referring now to FIGS. 14-15: FIG. 14 is perspective view of anothercomposite lintel structure 5 having an adjustable stiffener 90 mountedto the horizontal leg 10 of the lintel 5 using T-bars 120 and T-channels110 and to the vertical leg 20 using fasteners and fastener holes. Thealternate adjustable stiffener 90 comprises a triangular stiffenermember 95 rigidly attached to a stiffener bracket 98. More specifically,a stiffener bracket 98 is provided having a bracket vertical leg 92, anda bracket horizontal leg 94, to which the back edge and bottom edge ofthe stiffener member 95 is rigidly attached. The bracket vertical leg 92and the bracket horizontal leg 94 adjoin the front face 20 a and the topface 10 b respectively of the vertical and horizontal legs 20, 10, ofthe lintel 5. The overall dimensions of the vertical leg 20, horizontalleg 10 and stiffener 95 of the lintel 5 are as described above in theembodiments of the lintels in FIGS. 3-8. Furthermore the materials ofconstruction of the lintel 5 are as described above in the embodimentsof the lintels in FIGS. 3-8.

To accommodate the use of adjustable stiffener brackets 90, the top face10 b of the horizontal leg 10 and the bottom face 94 a of the brackethorizontal leg 94 also have one or more T-channels 110 and T-bars 120respectively therein and thereon allowing for insertion of the bracket90 therein. More specifically, the bottom face 94 a of the horizontalleg 94 has an essentially T-shaped bar 120 rigidly attached thereto andextending substantially normal to the surface 94 a thereof. The T-bar120 comprises a vertical T-leg 121 and a horizontal T-leg 122. Thevertical T-leg 121 is configured as a rectangular prism extending normalto the bottom face 94 a in the vertical dimension and preferably normalto the bracket vertical leg 92 in the depth dimension. The horizontalT-leg 122 is rigidly attached to the vertical T-leg 121 and is alsoconfigured as a rectangular prism having a greater width (in thehorizontal dimension) than the vertical T-leg 121. The horizontal T-leg122 extends substantially parallel to the bottom face 94 a of thebracket horizontal leg 94 in the vertical dimension and preferablynormal to the bracket vertical leg 92 in the depth dimension.

The horizontal leg 10 has a recessed T-channel 110 therein toaccommodate insertion of the T-bar 120 therein for retention of thebracket 90. The T-channel 110 comprises a vertical T-recess 111 and ahorizontal T-recess 112. The vertical T-recess 111 is configured as arectangular prismatic recess extending downward normal from the top face10 a into the horizontal leg 10 in the vertical dimension. Thehorizontal T-recess 112 is adjacent to the vertical T-recess 111 and isalso configured as a rectangular prism having a greater width (in thehorizontal dimension) than the vertical T-recess 111. The horizontalT-recess 122 extends substantially parallel to the top and bottom faces10 a, 10 b of the horizontal leg 10 in the vertical dimension andpreferably normal to the vertical leg 20 in the depth dimension. TheT-channel 110 is of substantially the same and preferably slightlylarger dimensions as the T-bar 120 to allow for insertion of the T-bar120 into the T-channel for retention of the attached bracket 90 therein,and allowing the bottom face 94 a of the bracket horizontal leg to abutthe top face 10 a of the lintel horizontal leg 10 as well as allowingthe back face 92 b of the vertical bracket leg 92 to abut the front face20 a of the lintel vertical leg 20.

Preferably the overall depth of the T-channel 110 (and vertical heightof the T-bar 120) is ⅓-⅔ of the overall thickness of the horizontal leg10 of the lintel, and most preferably approximately ½ of the horizontalleg 10 thickness. To this end the vertical dimension of the T-channelvertical recess 111 and T-bar 120 vertical leg 121 is ⅙-⅓ (andpreferably ¼) the over all thickness of the horizontal leg 10, and thevertical dimension of the T-channel horizontal recess 111 and T-bar 120horizontal leg 122 is ⅙-⅓ (and preferably ¼) the over all thickness ofthe horizontal leg 10. Furthermore, the width in the horizontaldimension of the T-channel vertical recess 111 and T-bar 120 verticalleg 121 is ⅙-⅓ (and preferably ¼) the over all thickness of thehorizontal leg 10, and the width in the horizontal dimension of theT-channel horizontal recess 111 and T-bar 120 horizontal leg 122 is ⅓-⅔(and preferably ½) the over all thickness of the horizontal leg 10.Exemplary dimensions (Height×Width×Depth) for a T-bar 120 and T-channel110 are vertical portions 121, 111 of ¼×¼×3-⅝ inches and horizontalportions 122, 112 of ¼×½×3-⅝ inches.

To allow for placement of the bracket 90 on the lintel 5 and providing asubstantially horizontal surface transition between the top face 10 a ofthe horizontal leg 10 and the top face 94 b of the bracket horizontalleg 94, a recess 11 may be provided in the top face 10 b of thehorizontal leg 10. Preferably the depth of the recess 11 isapproximately the same as the thickness of the bracket horizontal leg94. The thickness of the horizontal bracket 94 is approximately 1/10 to¼ the overall thickness of the horizontal 10 of the lintel 5. The widthof the recesses 11 (if any) is preferably the same as or slightly largerthan the width of the bracket 90 to allow for slight left and/or rightadjustment of the bracket 90 within the recesses 11. The bracket 90 ispreferably at least ½ inch in width, and most preferably 3-4 inches inwidth. Thus the recess 11 is preferably 3-5 inches in width to allow foradjustment of the bracket left or right by up to 1 inch.

To provide for securing of the adjustable stiffener 90 once it is placedin the desired position, snap fastener 99 may be provided extending fromthe back face 92 b of the vertical bracket leg 92 and for placement intosnap holes 93 in the front face 20 a of the vertical leg 20 of thelintel 5. Preferably the snap fasteners 99 are slightly flared(gradually increasing in diameter from the front to back direction).Preferably the snap holes 93 are also slightly flared (graduallyincreasing in diameter from the front to back direction). This allowsfor placement of a snap fastener 99 into a snap hole 93 in such a mannerthat the fastener 99 cannot be removed from the hole 93 after beinginserted therein.

Rather than using the snap fasteners 99 and snap holes 93 as describedherein above, to provide for securing of the adjustable stiffener 90once it is placed in the desired position, bracket affixation holes 41may be provided through the vertical bracket leg 92 and through thevertical leg 20 affixation holes 40 of the lintel 5, for placement offasteners 45 therethrough. Placement of a fastener 45 through theaffixation holes 40, 41 allows for attachment of the composite lintel 5to the building structure and fixation of the adjustable stiffener 90relative to the lintel 5.

Referring to FIGS. 14 and 16-18: Rather than using the T-channels andT-bars 110, 120 as described above, this embodiment of a lintel 5 andstiffener bracket 90 may instead dovetail fasteners (as described hereinbelow) aligned along the same axis (normal to the front face 20 a of thevertical leg 20) as the T-channels and T-bars 110, 120 above.

Referring now to FIGS. 16-18: FIG. 16 is perspective view of anothercomposite lintel structure 6 having an adjustable stiffener 100 mountedto the horizontal leg 10 and to the vertical leg 20 of the lintel 6using dovetails 130 and dovetail channels 140. The alternate adjustablestiffener 100 comprises a triangular stiffener member 105 rigidlyattached to a stiffener bracket 108. More specifically, a stiffenerbracket 108 is provided having a bracket vertical leg 102, and a brackethorizontal leg 104, to which the back edge and bottom edge of thestiffener member 105 is rigidly attached. The bracket vertical leg 102and the bracket horizontal leg 104 adjoin the front face 20 a and thetop face 10 b respectively of the vertical and horizontal legs 20, 10,of the lintel 6. The overall dimensions of the vertical leg 20,horizontal leg 10 and stiffener 105 of the lintel 6 are as describedabove in the embodiments of the lintels in FIGS. 3-8. Furthermore thematerials of construction of the lintel 6 are as described above in theembodiments of the lintels in FIGS. 3-8.

To accommodate the use of adjustable stiffener brackets 100, the frontface 20 a of the vertical leg 20 and the back face 102 a of the bracketvertical leg 102 also have one or more (preferably 2 parallel)dovetail-channels 140 and dovetails 130 respectively therein and thereonallowing for insertion of the bracket 100 therein. More specifically,the back face 102 a of the vertical leg 102 has at least one (preferablytwo parallel) essentially trapezoidal-shaped bar(s) (dovetail) 130rigidly attached thereto and extending substantially normal to thesurface 102 a thereof. The dovetail 130 is configured as a trapezoidalprism rigidly attached to the back surface 102 a of the bracket verticalleg 102 at the trapezoidal prism's smaller opposing parallel face andextending normal to the back face 102 a in the horizontal dimension andpreferably parallel to the bracket horizontal leg 104 in the lengthdimension.

The vertical leg 20 has at least one (preferably two parallel) recesseddovetail-channels 140 therein to accommodate insertion of the dovetails130 therein for retention of the bracket 100. The dovetail-channel 140comprises a recess shaped as a substantially trapezoidal prism. Thedovetail channel 140 is configured as a trapezoidal prismatic recessextending normally into front face 20 a into the vertical leg 20 in thedepth dimension, with the smaller opposing parallel face of thetrapezoidal prism forming the opening in the front face 20 a of thevertical leg 20. The dovetail-channel 140 is of substantially the sameand preferably slightly larger dimensions as the dovetail 130 to allowfor insertion of the dovetail 130 into the dovetail-channel 140 forretention of the attached bracket 100 therein, and allowing the backface 102 a of the bracket vertical leg 102 to abut the front face 20 aof the lintel vertical leg 20 as well as allowing the bottom face 104 aof the horizontal bracket leg 104 to abut the top face 10 a of thelintel horizontal leg 10.

Preferably the overall depth of the dovetail-channel 140 (and depth ofthe dovetail 130) is ⅓-⅔ of the overall thickness of the vertical leg 20of the lintel, and most preferably approximately ½ of the vertical leg20 thickness. Furthermore, the height of the smaller parallel face ofthe trapezoidal prism is ⅙-⅓ (and preferably ¼) the over all thicknessof the vertical leg 20, and the width in the height of the largerparallel face of the trapezoidal prism ⅓-⅔ (and preferably ½) the overall thickness of the vertical leg 20. Exemplary dimensions(Length×Height×Depth) for a dovetail 130 and dovetail-channel 140 aretrapezoidal prisms 2-10 feet×(¼×½)×½ inches.

The bottom face 104 a of the horizontal leg 104 also has at least oneessentially trapezoidal-shaped bar (dovetail) 130 rigidly attachedthereto and extending substantially normal to the surface 104 a thereof.The dovetail 130 is configured as a trapezoidal prism rigidly attachedto the bottom surface 104 a of the bracket horizontal leg 104 at thetrapezoidal prism's smaller opposing parallel face and extending normalto the bottom face 104 a in the vertical dimension and preferablyparallel to the bracket vertical leg 102 in the depth dimension andparallel to the horizontal leg in the length dimension.

The horizontal leg 10 also has at least one recessed dovetail-channel140 therein to accommodate insertion of the dovetail 130 therein forretention of the bracket 100. The dovetail-channel 140 comprises arecess shaped as a substantially trapezoidal prism. The dovetail channel140 is configured as a trapezoidal prismatic recess extending downwardnormal from the top face 10 b into the horizontal leg 10 in the verticaldimension, with the smaller opposing parallel face of the trapezoidalprism forming the opening in the top face 10 b of the horizontal leg 10.The dovetail-channel 140 is of substantially the same and preferablyslightly larger dimensions as the dovetail 130 to allow for insertion ofthe dovetail 130 into the dovetail-channel 140 for retention of theattached bracket 100 therein, and allowing the bottom face 104 a of thebracket horizontal leg to abut the top face 10 b of the lintelhorizontal leg 10 as well as allowing the back face 102 a of thevertical bracket leg 92 to abut the front face 20 a of the lintelvertical leg 20.

Preferably the overall depth of the dovetail-channel 140 (and verticalheight of the dovetail 130) is ⅓-⅔ of the overall thickness of thehorizontal leg 10 of the lintel, and most preferably approximately ½ ofthe horizontal leg 10 thickness. Furthermore, the width in thehorizontal dimension of the smaller parallel face of the trapezoidalprism is ⅙-⅓ (and preferably ¼) the over all thickness of the horizontalleg 10, and the width in the horizontal dimension of the larger parallelface of the trapezoidal prism ⅓-⅔ (and preferably ½) the over allthickness of the horizontal leg 10. Exemplary dimensions(Height×Width×Depth) for a dovetail 130 and dovetail-channel 140 aretrapezoidal prisms ½×(¼×½)×3⅝ inches.

Referring now to FIG. 18: While the above description of the lintel 6provided for dovetails 130 on the bracket 100 and dovetail channels 140in the horizontal and vertical legs 10, 20 of the lintel 6, it is withinthe scope of the invention to have one or more dovetails 130 on thesurfaces of the horizontal and vertical legs 10, 20 of the lintel 6, andto have one or more dovetail channels 140 in the bracket 100.Furthermore, it is within the scope of the invention that the lintellegs 10, 20 have both dovetails 130 and dovetail channels 140 thereinwith cooperating respective dovetail channels 140 and dovetails 130in/on the surfaces of the bracket 100.

To provide for securing of the adjustable stiffener bracket 100 once itis placed in the desired position, bracket affixation holes 41 may beprovided through the vertical bracket leg 102 and through the verticalleg 20 affixation holes 40 of the lintel 6, for placement of fasteners45 therethrough. Placement of a fastener 45 through the affixation holes40, 41 allows for attachment of the composite lintel 6 to the buildingstructure and fixation of the adjustable stiffener 100 relative to thelintel 6.

Referring now to FIGS. 19-20: Although the most common use for a lintelis to span a horizontal opening in a building structure, lintels mayalso be used on non-horizontal opening such as for dormers, eaves, roofsand arches. FIG. 19 is a front elevation view of an angled lintelstructure 7 configured in the form of a roof, dormer or eave angle.Essentially, it is the union of two lintel structures (as in embodiments1 and 2) which are joined together at an angle φ with respect to eachother. This angle may vary from as few as 10 degrees to as much as 160degrees depending on the architecture of the building. The most commonangles are 90 degrees, 45 degrees, 30 degrees and 60 degrees. FIG. 20 isfront elevation view of a lintel structure 8 configured in the form ofan arched lintel 8. The arched lintel 8 is of substantially semicircularconstruction. Arched openings in building structures vary in curvature,therefore the radius of curvature of the arch angle may vary from as fewas 2 feet to as many as 20 feet. Typical arched opening require anarched lintel 8 having a radius of approximately 4 feet. Alternatively,the arched lintel 8 may be elliptical or of variable curvature as suitedfor the design of the arched opening in the building structure. Thematerials of construction of the angled lintel 7 and arched lintel aresubstantially as described herein above for the lintels 1, 2 of FIGS.3-8. Both the angled lintel 7 and the arched lintel 8 may also beprovided with adjustable stiffeners 60, 70, 80, 90 or 100 as describedherein above for the lintels 3, 4, 5 and 6 of FIGS. 9-18.

While the principles of the invention have now been made clear inillustrated embodiments, there will immediately be obvious to thoseskilled in the art, many modifications of structure, proportions,elements, materials, and components used in the invention, which areparticularly adapted for specific environments and applicationrequirements without departing from those principles. Therefore, by theappended claims, the applicants intend to cover any modifications andother embodiments as incorporate those features which constitute theessential features of this invention.

1. A lintel member for spanning an opening in a building structure andsupporting building materials thereon, comprising: a vertical leg havinga top portion and a bottom portion and a front face and a back face; anda horizontal leg having a front portion and a back portion and a topface and a bottom face; said vertical leg bottom portion being rigidlyaffixed to said horizontal leg back portion, thereby defining asubstantially L-shaped bracket; and load transference means connectedbetween said horizontal leg and said vertical leg; and wherein saidvertical leg is configured to be attached to an underlying buildingstructure; and wherein said horizontal leg is configured to supportbuilding materials thereon; and wherein said load transference means isconfigured to transfer a load exerted on said horizontal leg by saidbuilding materials through said load transference means to said verticalleg and said underlying building structure; and wherein the material ofconstruction of said vertical leg and horizontal leg comprises acorrosion resistant, moisture impermeable thermoplastic material.
 2. Alintel member according to claim 1, wherein said load transference meanscomprises: a substrate having a vertical portion between said front andback faces of said vertical leg and a horizontal portion between saidtop and bottom faces of said horizontal leg; and wherein a bottomportion of said vertical portion of said substrate is rigidly connectedto a back portion of said horizontal portion of said substrate; andwherein said substrate is configured to transfer a load exerted on saidhorizontal leg by said building materials through said horizontalportion of said substrate to said vertical portion of said substrate andto said vertical leg and said underlying building structure.
 3. A lintelmember holder according to claim 1, wherein said load transference meanscomprises: a stiffener attached between said horizontal leg and saidvertical leg of said lintel member; said stiffener comprising asubstantially triangular member having a back edge, a bottom edge, adiagonal edge, and left and right side faces; said back edge of saidstiffener being adapted to be attached to said front face of saidvertical leg; said bottom edge of said stiffener being adapted to beattached to said horizontal leg.
 4. A lintel member according to claim2, wherein said load transference means further comprises: a stiffenerattached between said horizontal leg and said vertical leg of saidlintel member; said stiffener comprising a substantially triangularmember having a back edge, a bottom edge, a diagonal edge, and left andright side faces; said back edge of said stiffener being adapted to beattached to said front face of said vertical leg; said bottom edge ofsaid stiffener being adapted to be attached to said horizontal leg.
 5. Alintel member according to claim 4, wherein said substrate furthercomprises: a substrate diagonal portion between said side faces of saidstiffener; wherein said diagonal portion of said substrate is rigidlyconnected to said vertical portion and said horizontal portion of saidsubstrate; and wherein said horizontal portion of said substrate isconfigured to transfer a load exerted on said horizontal leg by saidbuilding materials through said horizontal portion of said substrate tosaid vertical portion of said substrate and to said vertical leg andsaid underlying building structure.
 6. A lintel member according toclaim 1, further comprising: at least one weep hole extending throughfrom said top surface to said bottom surface of said horizontal leg forallowing drainage of moisture from said top surface to said bottomsurface of said horizontal leg.
 7. A lintel member according to claim 2,further comprising: at least one weep hole extending through from saidtop surface to said bottom surface of said horizontal leg and saidhorizontal portion of said substrate for allowing drainage of moisturefrom said top surface to said bottom surface of said horizontal leg;wherein said at least one weep hole through said substrate has aperipheral surface covered by said thermoplastic material.
 8. A lintelmember according to claim 1, further comprising: a plurality ofaffixation holes extending through from said front surface to said backsurface of said vertical leg for allowing attachment of said verticalleg to a plurality of affixation locations on said underlying buildingstructure; and a plurality of fasteners adapted to be placed throughsaid plurality of affixation holes and attachment to said underlyingbuilding structure.
 9. A lintel member according to claim 2, furthercomprising: a plurality of affixation holes extending through from saidfront surface to said back surface of said vertical leg and saidvertical portion of said substrate for allowing attachment of saidvertical leg to a plurality of affixation locations on said underlyingbuilding structure; and a plurality of fasteners adapted to be placedthrough said plurality of affixation holes and attachment to saidunderlying building structure; wherein said plurality of affixationholes through said substrate has a peripheral surface covered by saidthermoplastic material.
 10. A lintel member according to claim 1,wherein said thermoplastic material is selected from the group moistureimpermeable, corrosion resistant, high strength thermoplastics materialsconsisting of: Acrylonitrile/Methylacrylate copolymer; RegeneratedCellulose; CA; CAB; Cyclo-olefin copolymer; E-CTFE; ETFE; EP; FKM; PAN;ABS; PA 4,6; PA 6; PA 6,6; PA 6,6 30% GFR; PA 11; PA 12; PAI; PolyaramidPolyparaphenylene terephthalamide; Polyaramid Polymetaphenyleneisophthalamide; PBI; PBT; PBT 30% GFR; PC; Polycarbonate—30% Glass FibreFilled; PCTFE; PEEK; PEI; PES; Polyethylene—Carbon filled; HDPE; LDPE;UHMW PE; PEN; PET, PETP; PHB; PHB92/PHV 8; PI; PMMA; Acrylic;Polymethylpentene; POMC; POMH; Polyphenyleneoxide PPO (modified), PPE(modified); PPO 30% GFR; PPS; PPS—40% GFR; Polyphenylsulphone; PP; PS;PS—X—Linked; PTFE; PTFE 75/Glass 25; PTFE 25% GF; UPVC; PVF; PVDC; PVDF;Silicone Elastomer; Teflon; and Teflon PFA.
 11. A lintel memberaccording to claim 2, wherein said thermoplastic material is selectedfrom the group moisture impermeable, corrosion resistant, high strengththermoplastics consisting of: Acrylonitrile/Methylacrylate copolymer;Regenerated Cellulose; CA; CAB; Cyclo-olefin copolymer; E-CTFE; ETFE;EP; FKM; PAN; ABS; PA 4,6; PA 6; PA 6,6; PA 6,6 30% GFR; PA 11; PA 12;PAI; Polyaramid Polyparaphenylene terephthalamide; PolyaramidPolymetaphenylene isophthalamide; PBI; PBT; PBT 30% GFR; PC;Polycarbonate—30% Glass Fibre Filled; PCTFE; PEEK; PEI; PES;Polyethylene—Carbon filled; HDPE; LDPE; UHMW PE; PEN; PET, PETP; PHB;PHB92/PHV 8; PI; PMMA; Acrylic; Polymethylpentene; POMC; POMH;Polyphenyleneoxide PPO (modified), PPE (modified); PPO 30% GFR; PPS;PPS—40% GFR; Polyphenylsulphone; PP; PS; PS—X—Linked; PTFE; PTFE75/Glass 25; PTFE 25% GF; UPVC; PVF; PVDC; PVDF; Silicone Elastomer;Teflon; and Teflon PFA; and wherein the material of construction of saidsubstrate is selected from the group of high strength materialsincluding: iron; steel; aluminum; tin; titanium; beryllium; carbon;carbon fibers; concrete; glass reinforced plastics; carbon fiberreinforced plastics; and mixtures, oxides and alloys thereof.
 12. Alintel member according to claim 3, wherein said stiffener furthercomprises: a stiffener bracket comprising; a bracket vertical leg havinga front face and a back face and a top edge and a bottom edge; said backedge of said substantially triangular member being attached to saidfront face of said bracket vertical leg; a bracket horizontal leg havinga top face and a bottom face and a back edge and a front edge; said backedge of said bracket horizontal leg being attached to said bottom edgeof said bracket vertical leg; said bottom edge of said substantiallytriangular member being attached to said top face of said brackethorizontal leg; and stiffener bracket attachment means on said bracketvertical leg or said bracket horizontal leg; said stiffener bracketattachment means being adapted for adjustable attachment of said bracketvertical leg to a plurality of attachment locations on said vertical legor adjustable attachment of said bracket horizontal leg to a pluralityof attachment locations on said horizontal leg.
 13. A lintel memberaccording to claim 12, wherein said stiffener bracket attachment meansis selected from the group consisting of: dovetails on said bottom faceof said bracket horizontal leg with cooperating dovetail channels insaid top face of said horizontal leg; dovetails on said back face ofsaid bracket vertical leg with cooperating dovetail-channels in saidfront face of said vertical leg; T-bars on said bottom face of saidbracket horizontal leg with cooperating T-channels in said top face ofsaid horizontal leg; T-bars on said back face of said bracket verticalleg with cooperating T-channels in said front face of said vertical leg;and combinations thereof.
 14. A lintel member according to claim 12,wherein said stiffener bracket attachment means further comprises: afront plate having a top and a bottom edge, said top edge of said frontplate being connected to said front edge of said stiffener horizontalleg; and a bottom plate having a front edge, said front edge of saidbottom plate being connected to said bottom edge of said front plate;wherein said stiffener horizontal leg, said front plate and said bottomplate are adapted to be located adjacent a plurality of locations alongsaid top face, said front edge and said bottom face of said horizontalleg, respectively.
 15. A lintel member according to claim 12, whereinsaid stiffener bracket attachment means further comprises: a top platehaving a front and a back edge, said front edge of said top plate beingconnected to said top edge of said stiffener vertical leg; and a backplate having a top edge, said top edge of said back plate beingconnected to said back edge of said top plate; wherein said stiffenervertical leg, said top plate and said back plate are adapted to belocated adjacent a plurality of locations along said front face, saidtop edge and said back face of said vertical leg, respectively.
 16. Alintel member according to claim 12, wherein said stiffener bracketattachment means further comprises: a first recess in said top face ofsaid horizontal leg adjacent a first groove between the top face, bottomface and front edge of said horizontal leg; wherein said front edge ofsaid stiffener bracket horizontal leg is adapted to be retained withinsaid first groove.
 17. A lintel member according to claim 12, whereinsaid stiffener bracket attachment means further comprises: a secondrecess in said top face of said horizontal leg adjacent a second groovebetween the front face, back face and top edge of said vertical leg;wherein said top edge of said stiffener bracket vertical leg is adaptedto be retained within said second groove.
 18. A lintel member accordingto claim 17, wherein said stiffener bracket attachment means furthercomprises: a second recess in said top face of said horizontal legadjacent a second groove between the front face, back face and top edgeof said vertical leg; wherein said top edge of said stiffener bracketvertical leg is adapted to be retained within said second groove.
 19. Alintel member according to claim 14, wherein said stiffener bracketattachment means further comprises: a top plate having a front and aback edge, said front edge of said top plate being connected to said topedge of said stiffener vertical leg; and a back plate having a top edge,said top edge of said back plate being connected to said back edge ofsaid top plate; wherein said stiffener vertical leg, said top plate andsaid back plate are adapted to be located adjacent a plurality oflocations along said front face, said top edge and said back face ofsaid vertical leg, respectively.
 20. A lintel member according to claim12, wherein said stiffener bracket attachment means further comprises: aplurality of fasteners in said stiffener bracket vertical leg, saidplurality of fastener being selected from the group consisting of: snapfasteners, threaded fasteners, nails, adhesives and sealing coatedfasteners.